Micro-Layer Tubular Extrusion Without Weld Lines
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Solution Overview
Problem
Conventional extrusion die systems for producing tubular products with nano-sized features often require rotating components, which can introduce weld lines and limitations in product strength, and struggle to create seamless tubes without knit lines.
Innovation Solution
A non-rotating extrusion assembly that forms multiple laminated flow streams by compressing, dividing, and overlapping ribbon-shaped streams, generating nano-sized features and forming tubular products with an exit flow passage skewed at a helical pitch angle to create a seamless, strong tubular micro-layer product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional extrusion die systems use rotating components to produce tubular products, then the products can be formed with nano-sized features, but weld lines are introduced and product strength is limited
Solution Approach 1:
The extrusion process is segmented into multiple sequential stages, each creating additional laminations. The material flow is divided into multiple streams that are repeatedly compressed, divided, and overlapped to generate progressively thinner laminations with nano-sized features, while maintaining a non-rotating die configuration to eliminate weld lines
Solution Approach 2:
The die system implements periodic cycles of compression, division, and lamination of the material flow. Each cycle multiplies the number of laminations and reduces their thickness, creating nano-sized grain features through repeated periodic action without requiring rotating components
2Ease of manufacture
If conventional extrusion processes form tubular products, then products can be manufactured, but knit lines and weld lines are created that reduce structural integrity
Solution Approach 1:
Instead of using rotating dies that create knit lines by twisting the material, this invention uses a non-rotating die system where the material flow is manipulated through sequential compression and lamination stages. The material is folded back on itself in a controlled manner to form seamless tubes without traditional knit lines or weld lines, inverting the conventional approach to tubular extrusion
3Manufacturing precision
If micro-layer extrusion forms sheets first then tubes, then nano-sized features can be achieved, but weld lines are created at the separation between microlayers
Solution Approach 1:
The die system performs preliminary actions by pre-forming the material into multiple laminated streams with nano-sized features before the material exits the die. The sequential compression and lamination stages prepare the material structure in advance, creating the desired grain features and seamless tubular configuration before forming, eliminating the need for post-forming weld operations
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables the production of tubular products with enhanced strength and flexibility by eliminating weld lines and achieving nano-sized features without the need for rotating components, resulting in superior mechanical properties and design flexibility.
Implementation Method 1
subjecting the ribbon shaped flow streams to multiple sequences of stages, wherein in each of the sequences the flow streams are compressed
Implementation Method 2
forming a first set of multiple laminated flow streams from the extruded flow
Implementation Method 3
forming tubular products with an exit flow passage skewed at a helical pitch angle to create a seamless, strong tubular micro-layer product
Data Source
AI summary
A system and method are presented in which a flow of plastic is extruded to obtain nano-sized features by forming multiple laminated flow streams, flowing in parallel through the non-rotating extrusion system. Each of the parallel laminated flow streams are subjected to repeated steps in which the flows are compressed, divided, and overlapped to amplify the number of laminations. The parallel amplified laminated flows are rejoined to form a combined laminated output with nano-sized features. The die exit is formed to provide a tubular shape.